Robotic loader for surgical stapling cartridge

ABSTRACT

A means and method for inserting drivers into a surgical stapling cartridge, including a pallet that holds the cartridge firmly. The pallet has a central slot and laterally positioned lip members that are biased toward the slot. The cartridge is positioned in the slot and the lip members are released to extend their lips over the lateral flanges on the cartridge, thereby holding the cartridge in position. A finger extends into a recess formed at one end of the cartridge, thereby positively positioning the cartridge in the slot. The cartridge is released for removal by a tongue inserted between the lip members, thereby separating them by displacement.

CROSS-REFERENCES TO RELATED APPLICATIONS

(Not Applicable)

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT

(Not Applicable)

REFERENCE TO A “MICROFICHE APPENDIX”

(Not Applicable)

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a means and a method for loading asurgical stapling cartridge.

2. Description of the Related Art

It is known in the prior art mechanically to insert drivers intosurgical stapling cartridges, as shown in U.S. Pat. No. 5,836,147 toSchnipke, U.S. Pat. No. 5,635,928 to Schnipke, and U.S. Pat. No.6,158,205 to Schnipke et al., all of which are incorporated herein byreference. However, the mechanisms for this insertion require dexterityby trained people who are able to position the frames that contain thedrivers and the cartridges, and actuate the machines to insert the tinydrivers into the precisely formed holes in the cartridges. After afraction of the drivers are inserted by one machine, the cartridge isthen manually transported to the next machine, which inserts anotherfraction of the drivers.

If any drivers are improperly inserted into a cartridge, or are notinserted, the cartridge is either discarded or repaired, which meansthat errors in insertion of the tiny parts can result in time and/orproduct lost. Such problems in manufacturing occur due to human error,and therefore it is desirable to mechanize the process to reduce thenumber of opportunities for error.

BRIEF SUMMARY OF THE INVENTION

The invention is a moveable pallet used in a system in which roboticarms load cartridges. The pallet firmly holds a surgical staplingcartridge as drivers are inserted therein. The pallet comprises a basehaving a lower surface for seating on a conveyor. An elongated slot isformed in an upper surface of the base for holding the cartridge. Afirst cartridge-retaining lip member is movably mounted to the base on afirst side of the slot, said first lip member being biased toward theslot. The lip member has a lip extending into the slot. A secondcartridge-retaining lip member is mounted to the base on a second sideof the slot. The second lip member is preferably moveable and biasedtoward the slot, and it has a lip extending into the slot.

A gap is formed between the first and second lip members to receive atongue that is inserted upwardly through an aperture in the base. Thetongue seats against opposing surfaces of the lip members and displacesthe lip members away from the slot to release the cartridge. A finger ismounted to the base near a first longitudinal end of the slot, andextends into the slot for seating within a recess of the cartridge.

A preferred pallet has at least one tapered cavity formed in the lowersurface of the base for receiving a foot for positively positioning thepallet horizontally. The preferred pallet also has at least one verticalregistration surface that seats against at least two verticalregistration arms for positively positioning the pallet vertically.

A tool is used for picking up a frame to which a plurality of driversfor the surgical stapling cartridge is mounted. The tool comprises aprime mover and a first finger drivingly linked to the prime mover. Thefirst finger has a first pair of transverse planar panels formed in aninwardly facing surface of the first finger. The first pair oftransverse planar panels is adapted to seat against correspondingsurfaces on the driver frame. A second finger is connected to the primemover, and has a second pair of transverse planar panels formed in aninwardly facing surface of the second finger that is substantiallyopposed to the inwardly facing surface of the first finger. The secondpair of transverse planar panels is adapted to seat againstcorresponding surfaces of the driver frame.

A method of filling a surgical stapling cartridge is also contemplated.The method comprises holding firmly a cartridge in the above-describedpallet, conveying the pallet to a first station, raising the palletabove the conveyor and inserting a plurality of drivers into thecartridge when the pallet is in a raised position. The pallet is nextlowered back onto the conveyor and conveyed to a second station.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a view in perspective illustrating the preferred pallet with acartridge in an operable position.

FIG. 2 is a view in perspective illustrating the cartridge holder, whichis a component of the pallet.

FIG. 3 is a view in perspective illustrating the plate, which is acomponent of the pallet.

FIG. 4 is a view in perspective illustrating the ring, which is acomponent of the pallet.

FIG. 5 is a view in perspective illustrating a lip member.

FIG. 6 is a side view in section through the line 6—6 of FIG. 1.

FIG. 7 is a side view in section through the line 7—7 of FIG. 1.

FIG. 8 is a view in perspective illustrating a preferred structure fordisplacing the lip members apart.

FIG. 9 is a view in perspective illustrating the T-shaped finger thatextends into a recess near one end of the cartridge to positivelyposition the cartridge in the pallet.

FIG. 10 is a view in perspective illustrating the preferred structurefor lifting the pallet and horizontally aligning it relative to amachine.

FIG. 11 is a view in perspective illustrating a preferred machine forinserting drivers into a cartridge, and a pair of cantilevered arms thatdefine the upper limit of the pallet travel above the conveyor.

FIG. 12 is a view in perspective illustrating a preferred socket.

FIG. 13 is a view in perspective illustrating a preferred socket.

FIG. 14 is a view in perspective illustrating the preferred end of armtooling for gripping the frame to which drivers are mounted.

FIG. 15 is a view in perspective illustrating a preferred pallet forholding supplies, such as drivers.

FIG. 16 is a view in perspective illustrating one finger of the specialend of arm tooling.

FIG. 17 is a view in perspective illustrating a second finger of thespecial end of arm tooling.

FIG. 18 is a view in perspective illustrating special end of arm toolingfor gripping swing tab frames, and shows a swing tab frame in anoperable position.

FIG. 19 is a view in perspective illustrating special end of arm toolingfor gripping swing tab frames.

FIG. 20 is a view in perspective illustrating a preferred pallet forholding supplies, such as swing tabs.

In describing the preferred embodiment of the invention which isillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific term so selected and it is to be understoodthat each specific term includes all technical equivalents which operatein a similar manner to accomplish a similar purpose. For example, theword connected or term similar thereto are often used. They are notlimited to direct connection, but include connection through otherelements where such connection is recognized as being equivalent bythose skilled in the art.

DETAILED DESCRIPTION OF THE INVENTION

The preferred pallet 10 is shown in FIG. 1 with a surgical staplingcartridge 12 mounted therein in an operable position. The pallet 10 isessentially made up of two components: the cartridge holder 20 shown inFIG. 2, and the base 14 shown in FIGS. 3 and 4. The base 14 is made oftwo subcomponents: the plate 16 and the ring 18. The plate 16 and thecomponents of the cartridge holder 20 are preferably made of steel. Theplate 16 forms a rigid frame to which the other components of the pallet10 attach. The ring 18 is preferably made of a low friction polymer,such as is sold in association with the trademark DELRIN. The ring 18,plate 16 and the cartridge holding apparatus 20 are securely fixedtogether, such as by screws.

The lip members 22 and 24, both essentially identical to the lip member22 shown in FIG. 5, are mounted in the chambers 32 and 34, respectively,formed in the cartridge holder 20. The lip members 22 and 24 have lips26 and 28, respectively, both essentially identical to the lip 26 shownin FIG. 5. Each of the lip members is housed in its respective chamberwith the lip member seating against the surfaces that define thechamber, but with the ability of the lip members to be displacedlaterally toward and away from the slot 40. Each lip member is biasedtoward the slot 40, such as by coil springs. The cover panels 42 and 44keep the lip members from coming out of the chambers, but permit the lipmembers to slide within the chamber.

In their operable position show in FIG. 1, the lips 26 and 28 extendfrom the chambers 32 and 34 into the slot 40, which is the region of thepallet 10 in which the cartridge 12 is held when it is mounted in thepallet 10 (see FIG. 2). The cartridge 12 is restrained in the slot 40 bythe lips 26 and 28 extending over the lateral flanges on the cartridge12, which lateral flanges are conventional for surgical staplingcartridges of the type shown. Thus, the cartridge is held firmly andrigidly to the pallet 10, and cannot be removed without either breakingthe flanges or retracting the lips 26 and 28 away from the flanges.

Before the pallet 10 is first loaded with a cartridge, the lips 26 and28 are retracted by the structure shown in FIG. 8. The pallet 10 islifted off of a conveyor on which it rests (not viable) by a primemover, such as the pneumatic ram 59, which displaces the plate 61upwardly. The plate 61 has rigidly mounted feet 71, 73, 75 (and anotherfoot that is not visible in FIG. 8) that cooperate to align and lift thepallet 10 as described below. After the pallet 10 is lifted apredetermined distance, its upper surface seats against the undersidesof the rigid flanges 63 and 65, which prevent any upward movement beyondthe flanges.

Also rigidly mounted to the plate 61 is a tongue that is aligned with anaperture 50, shown in FIG. 3, formed through the plate 16. As the plate61 is displaced upwardly before the feet contact the pallet, the tongue60 extends through the ring 18, through the aperture 50 and through theaperture 52 of the cartridge holder 20 shown in FIG. 2. The edges of thetongue 60 seat against the opposed, tapered surfaces (surface 27 on lipmember 22 and an essentially identical surface on lip member 24) of thelip members 22 and 24. This seating begins to displace the lip membersoutwardly away from the slot 40, and as the tongue is extended furtherinto the aperture 52 and the feet contact the pallet 10, the tongue 60further displaces the lip members 22 and 24 outwardly, therebyretracting the lips 26 and 28 from the slot 40. Once the lips 26 and 28are no longer in the slot 40, the cartridge 12 can be inserted in theslot 40, and the tongue can be withdrawn, thereby permitting the biasedlip members to be displaced inwardly to hold the cartridge 12.

The cartridge 12 is thus held in the pallet 10 by the slot and thecartridge holding apparatus. However, the cartridge 12 must also beprecisely positioned in the slot so that the apertures in the cartridge12 are correctly positioned relative to the machines, described below,that insert drivers into the cartridge. The T-shaped finger 54 ismounted in the T-shaped opening 62 in the cartridge holder 20. Thefinger 54 extends upwardly into the slot, and when the cartridge isplaced in the slot 40, the finger 54 extends into a recess formed in oneend on the underside of the cartridge 12 as shown in FIG. 6. The finger54 thus precisely positions the cartridge 12 in the slot 40 byrestricting the cartridge's movement in the plane of the pallet 10. Thelips 26 and 28 restrict movement of the cartridge 12 outside of theplane of the pallet 10.

Once the cartridge 12 is precisely positioned in the pallet 10, thepallet must be precisely positioned relative to each machine thatoperates on the cartridge 12. The pallet is preferably conveyed along bya conveyor system, such as a conventional conveyor sold by Flexlink AB.This conveyor transports pallets with cartridges between severalstations, each station having a machine that inserts drivers or a swingtab into a cartridge. The machines are essentially conventional, asdescribed herein and in the patents incorporated by reference. However,the cooperation of the pallets with the machines is not conventional, asdescribed below.

At each station, the pallet 10 is halted by a retractable pin thatextends into the path of the pallet 10 on the conveyor, thus preventingthe passage of the pallet. The pin preferably extends upwardly and thepallet is stopped when the pallet's leading edge strikes the pin. Thepin is positioned to stop the pallet when the pallet is positioneddirectly over the apparatus shown in FIG. 10, and directly below theapparatus shown in FIG. 11.

The apparatus shown in FIG. 10 includes a prime mover, which ispreferably the pneumatic ram 64, that is drivingly linked to the plate66. The plate 66 has four tapered feet 67, 68, 69, and 70. Correspondingto the feet 67-70 are the sockets 77, 78, 79 and 80, one of which isshown in FIGS. 12 and 13 and which is representative of all of thesockets 77-80. The sockets 77-80 are mounted to the pallet 10 by screws(not shown) extending through openings 77′, 78′, 79′ and 80′,respectively, shown in FIG. 2. The sockets 77-80 seat against theunderside of the cartridge holding apparatus 20, and are containedwithin apertures 82, 83, 84 and 85, respectively, formed in the base 16,and apertures 86, 87, 88 and 89, respectively, formed in the ring 18.

The tapered cavities of the sockets 77-80 receive the tapered feet67-70, respectively. Because the cavities and feet are tapered, a degreeof initial misalignment does not cause the pallet to stay misalignedrelative to the machine that will operate on the cartridge. The taperedstructures permit the misalignment to be corrected as the plate 66raises the pallet 10 off of the conveyor upwardly toward the machine 100shown in FIG. 11. Any misalignment of the pallet 10 relative to theplate 66 disappears as the tapered surfaces of the feet and cavitiesslide relative to one another during lifting. Thus, once the feet 67-70seat in the sockets 77-80, there is extremely precise alignment of thepallet 10 with the plate 66, thus precisely positioning the pallet 10horizontally relative to the machine.

As the pallet 10 is raised up to the machine 100, the upper surface ofthe pallet 10, and preferably the tops of the cover panels 42 and 44,seat against the undersides of the cantilevered arms 102 and 104. Theposition of the pallet 10 when the top surfaces of the cover panels 42and 44 seat against the arms 102 and 104 is precisely predetermined, sothat when this seating occurs, the pallet 10, and the attached cartridge12, are positioned for insertion of the drivers into the cartridge.Thus, the cooperation between the tapered feet and the tapered cavitiesregisters the horizontal position of the pallet 10 relative to themachine 100 as described above, and the cooperation between the uppersurfaces of the cover panels 42 and 44 and the cantilevered arms 102 and104 registers the vertical position of the pallet 10 relative to themachine 100.

Once the pallet 10 is in the aligned position, the machine 100 functionsin an essentially conventional manner to insert the drivers into thecartridge 12. As is known in the industry, such insertion ordinarilytakes place in several stations, each of which inserts a fraction of thetotal number of drivers. Thus, once the first fraction of drivers isinserted, the ram 64 lowers the pallet 10 back onto the conveyor, theretractable pin retracts and the conveyor conveys the pallet 10 to thenext station at which the process of lifting and inserting drivers, isrepeated, except that the next set of drivers is inserted.

The pallet 10 has a slot 19 in one side of the ring 18. The slot has awidth and a depth that permits the pin that stops the pallet 10 to passtherethrough. This accommodates the action of the retractable pin, whichis to retract momentarily when the pallet is supposed to be driven pastthe pin, and then protrude upwardly to its pallet stopping position evenwhile the just released pallet is still directly over the pin. The slot19 passes directly over the pin, and therefore the pin has no effect onthe pallet that was just released to be conveyed downstream. However,the pin does seat against and stop the leading edge of the next upstreampallet.

At some time drivers must be positioned in the machine 100 in order tobe inserted by the machine into a cartridge. A plurality of drivers iscommonly molded to a frame 108 during manufacture. The frame 108 is aconvenient structure used to grasp the plurality of drivers, which areotherwise too small to conveniently grasp and manipulate individually byhand. Thus, the plurality of drivers attached to the frame 108 can bepositioned by hand in the region 106 of the machine 100. Alternatively,the drivers can be positioned in the region 106 by a mechanism, such asa conventional robotic arm using a unique gripping tool.

In the preferred embodiment, many frames, such as the frame 108, arestacked on the rods 112 of the driver pallet 110, shown in FIG. 15. Theframes are aligned by hand or by another robotic arm, so that a roboticarm can pick them individually off of the pallet 110 and place them inthe region 106. A somewhat similar pallet 220 (FIG. 20) holds othersupplies, such as swing tabs, which are installed in cartridges atanother station. The tooling necessary to grasp the frames of thedrivers and the swing tabs is especially designed to work with theframes, and is described next.

The end of arm tooling for the robotic arm is shown in FIG. 14 graspingthe frame 108 between the tips of two fingers 114 and 116. The firstfinger 114 and the second finger 116 are drivingly linked to a primemover, such as the servomotor of the robotic arm, which displaces thefingers 114 and 116 relative to one another. Of course, only one fingerneed be driven by the servomotor and the other could be merely connectedto the robotic arm. The first finger 114 has an inwardly facing surface124, and the second finger has an inwardly facing surface 126, which arepreferably in close proximity to one another once the fingers grasp theframe 108 and the arm moves the frame 108 to the region 106.

The first finger 114 has a pair of transverse planar panels 130 and 131formed in the inwardly facing surface 124 near the tip of the finger114. The planar panels 130 and 131 are adapted to seat against thecorresponding surfaces 130′ and 131′ on the driver frame as shown inFIG. 14.

The second finger has a pair of transverse planar panels 134 and 135formed in the inwardly facing surface 126 near the tip of the finger116. The planar panels 134 and 135 are adapted to seat against thecorresponding surfaces 134′ and 135′ on the driver frame as shown inFIG. 14. By clamping the frame 108 between the fingers 114 and 116, therobotic arm can lift the frame 108 off of the pallet 110 and then moveit over to the region 106 with precision. The precision arises from theexact registration of the transverse panels 130 and 131 seating againstthe corresponding surfaces 130′ and 131′. Because the transverse panels130 and 131 form a V-shaped structure, that structure seats precisely inthe V-shaped intersection of the corresponding surfaces 130′ and 131′. Asimilar result arises because of the planar panels 134 and 135 seatingagainst the corresponding surfaces 134′ and 135′ of the frame 108.

There are also substantially parallel planar panels 132 and 133 thatintersect the transverse planar panels 130 and 131, respectively, at theends of the transverse planar panels 130 and 131 closest to the tip ofthe finger 114. These parallel panels 132 and 133 seat against theunderside of the frame 108 to positively position it along the length ofthe finger 114. The substantially parallel panels 136 and 137 intersectthe transverse planar panels 134 and 135, respectively, at the ends ofthe transverse planar panels 134 and 135 closest to the tip of thefinger 116. This arrangement of planar panels provides precision in theposition of the frame 108.

The station in which swing tabs are inserted in the cartridges has anadditional robotic arm that uses a special tool 201 to grip the swingtab frame 200, shown in FIGS. 18 and 19, and remove it from the pallet220 shown in FIG. 20. The tool 201 has fingers 202 and 204, which areforked to form legs, 206, 207, 208 and 209. The legs 206-209 havetransverse planar panels formed in the fingers near the tips in whichthe angled ends of the swing tab frame 200 are inserted to grip theframe 200 as shown in FIG. 18. These transverse planar panels aresubstantially equivalent in function to the planar panels describedabove in association with FIGS. 14, 16 and 17. Thus, the angled ends ofthe swing tab frame 200 extend into the cavities formed by thetransverse planar panels, and the fingers grip the frame 200therebetween under the force of a prime mover, such as a servomotor onthe robotic arm.

The entire process of putting cartridges in pallets, inserting driversand swing tabs, and conveying the pallets is computer controlled,inasmuch as each pallet is conveyed by the conveyor, which is startedand stopped (if necessary) by a central computer. Additionally, sensorsat each station detect whether a pallet is present at each station bydetecting a device mounted in the side of each pallet, such as the screw150 in the pallet 10 (FIG. 1). When a pallet is detected, the computeractuates the pneumatic ram apparatus to raise the pallet to the positionin which it can be operated on by the machine at that station. Once themachine is finished with its task, the computer actuates the ram tolower the pallet and the retractable pin is activated by the computer tobe retracted to permit the pallet to be conveyed further by theconveyor. Essentially all functions are either controlled or monitoredby the central computer. The only human monitoring, other than viewingthe apparatus for malfunctions, is the placing of cartridges in thepallet initially, removing the finished cartridges from the pallets andplacing supplies, such as driver frames and swing tab frames on thepallets that supply the robotic arms. However, it is contemplated thatall of these functions could be mechanized.

While certain preferred embodiments of the present invention have beendisclosed in detail, it is to be understood that various modificationsmay be adopted without departing from the spirit of the invention orscope of the following claims.

What is claimed is:
 1. A method of filling a surgical stapling cartridgewith drivers, the method comprising: (a) holding firmly a cartridge in apallet, the pallet comprising: (i) a base having a lower surface seatingon a conveyor; and (ii) means mounted on an upper surface of the basegripping the cartridge; (b) raising the pallet above the conveyor to amachine for inserting drivers; (c) said machine inserting a plurality ofdrivers into the cartridge when the pallet is in a raised position; and(d) lowering the pallet onto the conveyor.
 2. The method in accordancewith claim 1, further comprising the step of a robotic arm loading themachine with said plurality of drivers.
 3. The method in accordance withclaim 2, further comprising the step of a central computer connected tosaid robotic arm actuating said robotic arm.
 4. The method of claim 1,further comprising the steps of: (a) conveying the pallet to a firststation on the conveyor, said first station being where the machine ispositioned; and then (b) conveying the pallet to a second station on theconveyor.
 5. The method in accordance with claim 4, further comprisingthe step of inserting at least one tapered foot into at least onetapered cavity on the lower surface of the base, thereby horizontallyregistering the pallet relative to the machine.
 6. The method inaccordance with claim 5, further comprising the step of raising an uppersurface of the pallet into abutting engagement against at least onedownwardly facing surface of an arm, thereby vertically registering thepallet relative to the machine.